Knife block with storage slot blade sharpeners and cutlery set using same

ABSTRACT

A knife block may include a block body with a recessed portion and a block insert positioned at least partially within the recessed portion. The block insert may include a first knife slot and a second knife slot. The knife block may include a first knife sharpener coupled to the block insert, where the first knife slot is sized such that a first knife is sharpened by the first knife sharpener each time the first knife is removed from the first knife slot, and a second knife sharpener coupled to the block insert, where the second knife slot is sized such that a second knife is sharpened by the second knife sharpener each time the second knife is removed from the second knife slot. The knife block may include a first knife storage slot and a second knife storage slot.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/481,506, filed Apr. 7, 2017, which is a continuation of U.S. patentapplication Ser. No. 14/320,100, filed Jun. 30, 2014, now U.S. Pat. No.9,693,644, the disclosures of which are incorporated herein.

BACKGROUND 1. Field of the Disclosure

The present disclosure generally relates to cutlery implements and knifeblocks and more particularly to a knife block with a storage slot havinga sharpener positioned to contact a knife blade stored in the storageslot.

2. Description of Related Art

Knives of many types are well known and typically have a blade with acutting edge along at least one edge of the blade. The cutting edge ofthe knife blade on most knives becomes dull over time and as a result ofusing the knife. Dulling of the cutting edge may result from a widerange of use conditions. For example, the cutting edge of a knife blademay become dull through improper use, such as by using the knife to cutobjects on hard surfaces such as glass cutting boards or granite countertops. Also, a cutting edge of a knife blade may become dull simplythrough normal wear from everyday use of the knife.

In order to maintain the cutting edge on most knives, the blade must besharpened periodically. How often one sharpens the blade, i.e.,sharpening frequency, depends on when the user recognizes that it istime to sharpen the blade and whether the user remembers or bothers totake the time to do so. This can be problematic because some users willnot take the time to sharpen a blade even when they do recognize theneed. Other users may not even recognize the need to sharpen a blade andthus will not do so.

A further problem is that many users will use improper technique whensharpening a knife. Some users may not know the proper techniques or maynot know the proper tools to use for sharpening a knife, may not havethe proper tools available in order to properly sharpen a knife, orboth. Other users may know the proper tools to use, may have them athand, and may even know the proper techniques. However, many of theseusers may not have the patience or the skill necessary to properlysharpen a knife. The most common method of maintaining a cutting edge ona knife blade is to use honing steel to “hone” the knife edge. Honingessentially just realigns the very tip of the edge at a very small scaleto improve cutting ability. Sharpening removes material to put a newedge on the knife. Honing a knife edge using honing steel still requiresthat the user recognizes when to hone a knife, remembers to hone theknife blade cutting edge, and does so properly. If the user does notrecognize when to hone a blade, does not remember to do so, does so tooinfrequently, or does so improperly, the user can damage the cuttingedge and the knife blade. The same is true for sharpening a knife blade.

Commonly known methods that have been devised to address these problemsalso have their own disadvantages. Some cutlery sets include a productthat utilizes honing steel and that is provided with the set. This is aparticularly common solution and many cutlery sets include a knifeblock, a set of knives, and a removable, elongate honing steel element.The honing steel is often provided with its own storage slot in theblock. However, this method relies heavily on the consumer or end userwith regard to frequency of honing and the technique used. This alsodoes not sharpen the blade. Many users do not know how to hone a knifeblade using a piece of honing steel, much less how to sharpen the bladeusing other techniques, and many also may not have the skill necessaryto do so properly. As noted above, honing a cutting edge of a knifeblade does not technically sharpen the cutting edge. Instead, thetechnique primarily is just used as a technique to re-align orstraighten the cutting edge of the knife.

Others have developed off-the-shelf sharpeners for sharpening thecutting edge of knives. The end user must typically purchase thesharpener because this type of product does not come with the knife setor the cutlery set. Many of these types of sharpeners utilize both acarbide sharpener and a ceramic sharpener. The user is supposed to firstuse the carbide sharpener, which is the more aggressive of the twosharpeners, and then finish using the ceramic sharpener. However, thesesharpeners again require that the user remember to sharpen the knife andto know how to use the product. This product may, however, reduce thepossibility that the user employs improper technique. These types ofsharpeners are typically sold independent of the knives that areultimately to be sharpened. Thus, it sometimes occurs that the userpurchases a sharpener that is a mismatch for their knives, i.e., amismatch in the angles of the sharpener elements compared to the angleson the blades of the knives themselves. Electric versions of these typesof sharpeners also exist in the marketplace, but the same problems stillarise.

Others take their knives to a trained professional for sharpening. Thistechnique requires the user to take or send their knives to theprofessional. A professional may use the above methods, devices, andtechniques, but should do so properly. However, this still requires theuser to know or decide when to have their knives sharpened and requiresthe extra effort to get the knives to the professional. Having aprofessional sharpen one's knives is also typically quite costly. Thecost may inhibit the user from having their knives sharpened when itwould otherwise be the right time to do so. The cost can be prohibitivebecause many professionals still sharpen knives by hand on a belt orrotary sander, which is akin to the processes used to originallymanufacture the knife. Such time consuming skilled labor is often quiteexpensive. Most users will not have their knives professionallysharpened at all, or will do so only very infrequently because of thenecessary time and expense.

Some cutlery sets have been produced that have a knife block and onededicated sharpening slot in the block. The sharpening slot is not usedto house or store a knife. Instead, when a user decides that a knifeshould be sharpened, the user then takes the knife, inserts it into thesharpening slot, and moves the knife back and forth across the sharpenerin the sharpening slot. This method still relies on the consumer or userto determine when to sharpen a knife and then to remember to do so. Thetypical sharpening slot on these types of products is also aone-size-fits-all slot for the entire set of knives provided with theknife block. The slot must be sized to fit the largest knife in the set.This can make the sharpener less than optimal for sharpening the smallerknives in the set and can make the sharpener less than optimal for eventhe larger knives of the cutlery set.

SUMMARY

In one example according to the teachings of the present disclosure, aknife block has a block body and a plurality of knife storage slotsextending into the block body. A first knife sharpener is aligned with afirst slot of the plurality of knife storage slots and a second knifesharpener is aligned with a second slot of the plurality of knifestorage slots. The first and second knife sharpeners are each configuredto contact a blade of a knife stored in the corresponding first andsecond slots.

In one example, the first knife sharpener can be positioned to contact acutting edge of the blade when a knife is inserted into the first slot,withdrawn from the first slot, or both, and the second knife sharpenercan be positioned to contact a cutting edge of the blade when a knife isinserted into the second slot, withdrawn from the second slot, or both.

In one example, the first slot and the second slot can each have thesame length into the block body. In one example, the first and secondslots can each extend completely through the block body.

In one example, the first slot can have a different width across theblock body than the second slot.

In one example, the first slot can have a different height along theblock body than the second slot.

In one example, the first slot can be oriented lengthwise at a firstangle within the block body relative to a horizontal reference and thesecond slot can be oriented lengthwise at a second angle within theblock body relative to the horizontal reference. The first and secondangles can each be between about 40 degrees and about 55 degrees. Thefirst and second angles can be the same or can be different from oneanother. In one example, the first angle and the second angle can eachbe about 52.5 degrees.

In one example, the knife block can have at least a third knifesharpener along a third slot of the plurality of knife storage slots.The third knife sharpener can be configured to contact a blade of aknife stored in the third slot. Each of the first, second, and thirdslots can have at least a length into the block body, a width across theblock body, and/or a height along the block body that is different thanthe other of the first, second, and third slots.

In one example, at least one slot of the plurality of knife storageslots does not have a knife sharpener aligned with the at least oneslot.

In one example, the knife block can also include a recess in a face ofthe block body and at least the first and second slots can open into therecess. A block insert can be mounted in the recess. A first sub-slotand a second sub-slot can be formed through the block insert. The firstsub-slot can be aligned with both the first knife sharpener and thefirst slot, and the second sub-slot can be aligned with both the secondknife sharpener and the second slot. The first and second knifesharpeners can be carried by the block insert.

In one example, the knife block can include first and second indicia ona surface of the block body. The first indicia can be associated with afirst opening into the first slot and the second indicia can beassociated with a second opening into the second slot. The first andsecond indicia can relate to one or more knife characteristics and thefirst indicia can be different than the second indicia.

In one example according to the teachings of the present disclosure, acutlery set has a knife block with a block body and at least a firststorage slot and a second storage slot each extending into the blockbody from a face of the block body. At least a first knife sharpener isaligned with the first storage slot and a second knife sharpener isaligned with the second storage slot. A first knife has a first bladeand a first handle and a second knife has a second blade and a secondhandle. The first storage slot is sized to receive the first blade andthe second storage slot is sized to receive the second blade. The firstknife sharpener can contact and sharpen a knife edge of the first bladewhen the first knife is inserted into or withdrawn from the first slotand the second knife sharpener can contact and sharpen a knife edge ofthe second blade when the second knife is inserted into or withdrawnfrom the second slot.

In one example, the first storage slot has at least one sizecharacteristic that can be different from the like size characteristicof the second storage slot.

In one example, at least one size characteristic of the first storageslot can be different from the like size characteristic of the secondstorage slot. The size characteristics can be one or more of a lengthinto, a width across, and/or a height along the block body.

In one example, the first storage slot can be oriented at a first anglerelative to a horizontal reference and the second storage slot can beoriented at a second angle relative to the horizontal reference. In oneexample, the first and second angles can be different or can be thesame. In one example, the first and second angles can be between about40 degrees and about 55 degrees relative to the horizontal reference. Inone example, the first and second angles can be between 50 degrees and55 degrees relative to the horizontal reference.

In one example, the first blade can have at least one sizecharacteristic that is different than a like size characteristic of thesecond blade. In one example, the at least one size characteristic canbe one or more of a blade length, a blade width, and/or a blade height.

In one example, the cutlery set can include a block insert of the knifeblock that is mounted to the face of the block body. A first sub-slotcan pass through the block insert and can be aligned with the firststorage slot in the block body. A second sub-slot can pass though theblock insert and can be aligned with the second storage slot in theblock body. The first and second knife sharpeners can be carried by theblock and can be respectively aligned with the first and secondsub-slots.

In one example, the cutlery set can include a faceplate of the knifeblock that covers a block insert. The faceplate can have a first openingthat can be aligned with a first sub-slot through the block insert and asecond opening that can be aligned with a second sub-slot through theblock insert.

In one example, the cutlery set can include a first knife indiciavisibly carried on a portion of the first knife that can indicate acharacteristic of the first knife and can include a second knife indiciavisibly carried on a portion of the second knife that can indicate acharacteristic of the second knife. A first block indicia can be visiblycarried on a portion of the knife block and can be associated with thefirst storage slot. The first block indicia can match the characteristicof the first knife indicated by the first knife indicia. A second blockindicia can be visibly carried on a portion of the knife block and canbe associated with the second storage slot. The second block indicia canmatch the characteristic of the second knife indicated by the secondknife indicia.

In one example, a first knife indicium can be carried on an end of thefirst handle and a second knife indicium is carried on an end of thesecond handle. A similar or identical indicium can also be carried on aportion of the knife block associated with the respective first andsecond storage slots.

In one example, a first block indicia can be provided adjacent a firstopening on a faceplate of the knife block and a second block indicia canbe provided adjacent a second opening on the faceplate. The first andsecond openings can be associated with the first and second storageslots, respectively.

In one example, the first knife sharpener can contact and sharpen aknife edge of the first blade when the first knife is inserted into andwithdrawn from the first slot. The second knife sharpener can contactand sharpen a knife edge of the second blade when the second knife isinserted into and withdrawn from the second slot.

In one example, the cutlery set can have a face angle defined by theface of the block body and can have a bolster angle defined by the firstand second handles on the first and second knives, respectively. Thebolster angle can be substantially the same as the face angle.

In one example, the first knife sharpener can define a first sharpenerangle that can be greater than a first blade edge angle defined by theknife edge of the first knife. The second knife sharpener can define asecond sharpener angle that can be greater than a second blade edgeangle defined by the knife edge of the second knife. The first andsecond sharpener angles can be the same or can be different than oneanother. The first and second blade edge angles can be the same or canbe different than one another.

In one example according to the teachings of the present disclosure, acutlery set has a knife block with a block body and a set of knivesincluding at least a first knife having a first blade and a second knifehaving a second blade. An array of storage slots in the knife blockincludes at least a first storage slot and a second storage slot andeach extends into the block body from a face of the block body. Thefirst storage slot is specifically sized to receive the first blade andthe second storage slot is specifically sized to receive the secondblade. A block insert can be mounted to the face of the block body. Theblock insert has at least a first sub-slot through the block insertaligned with the first storage slot and a second sub-slot through theblock insert aligned with the second storage slot. A first knifesharpener is carried by the block insert and is constructed and arrangedspecifically to sharpen a knife edge on the first blade when the firstknife is inserted into or withdrawn from the first slot. A second knifesharpener is carried by the block insert and is constructed and arrangedspecifically to sharpen the second blade when the second knife isinserted into or withdrawn from the second slot.

In one example, the first blade and the second blade can be differentfrom one another in at least one or more of a blade length, a bladewidth, and/or a blade height.

In one example, the first and second storage slots can be different fromone another in at least one or more of a slot length, a slot width,and/or a slot height.

In one example, the first knife and the second knife can be differentfrom one another in at least one blade characteristic.

In one example, the cutlery set can include a first knife indiciavisibly carried on a portion of the first knife and can include a secondknife indicia visibly carried on a portion of the second knife. Thesecond knife indicia can be different from the first knife indicia. Afirst block indicia can be visibly carried on a portion of the knifeblock, can match the first knife indicia, and can be associated with thefirst storage slot. A second block indicia can be visibly carried on aportion of the knife block, can match the second knife indicia, and canbe associated with the second storage slot.

BRIEF DESCRIPTION OF THE DRAWINGS

Objects, features, and advantages of the present invention will becomeapparent upon reading the following description in conjunction with thedrawing figures, in which:

FIG. 1 shows a perspective front, top, and right side view of oneexample of a cutlery set constructed in accordance with the teachings ofthe present disclosure.

FIG. 2 shows a partial exploded view of the cutlery set of FIG. 1.

FIG. 3 shows a left side view of the cutlery set of FIG. 1.

FIG. 4 shows a right side cross-section view taken along line 4-4 of thecutlery set of FIG. 1.

FIG. 5 shows a perspective view of the cross-section of the cutlery setof FIG. 4.

FIG. 6 shows an exploded top, front, and left side perspective view ofthe knife block of the cutlery set of FIG. 1.

FIG. 7 shows an exploded bottom perspective view of an insert assemblyof the knife block of FIG. 6.

FIG. 8 shows a close-up and partial cut-away view taken from FIG. 5 of asharpener element of the insert assembly in FIG. 7.

FIG. 9 shows a top perspective view of part of a sharpener element ofFIGS. 7 and 8.

FIG. 10A shows a bottom and rear perspective view of the insert assemblyof FIG. 7 in an assembled condition and with the knives of the cutleryset of FIG. 1 inserted.

FIG. 10B shows a plan view into one of the knife storage slots, whichhas a sharpener element.

FIG. 10C shows a simplified view of a sharpener element comparing asharpener angle of the sharpener element and a blade edge angle of aknife blade.

FIG. 11 shows a left side view of the knife block of the cutlery set ofFIG. 1 with a knife of the cutlery set partially withdrawn from theknife block.

FIG. 12 shows a top view of at least a portion of another example of acutlery set constructed in accordance with the teachings of the presentdisclosure and having alternate indicia on the knives and the knifeblock.

FIG. 13 shows a top view of at least a portion of another example of acutlery set constructed in accordance with the teachings of the presentdisclosure and having alternate indicia on the knives and the knifeblock.

FIG. 14 shows a top view of at least a portion of another example of aknife block constructed in accordance with the teachings of the presentdisclosure.

FIG. 15 shows a top view of at least a portion of another example of aknife block constructed in accordance with the teachings of the presentdisclosure.

FIG. 16 shows a top, front, and right side perspective view of anotherexample of a knife block constructed in accordance with the teachings ofthe present disclosure.

FIG. 17 shows a top, front, and right side perspective view of anotherexample of a knife block constructed in accordance with the teachings ofthe present disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE

The present disclosure is directed to examples of a knife block and of acutlery set that are configured and arranged to solve or improve uponone or more of the above-noted and/or other problems and disadvantageswith prior known knives, sharpening techniques, knife blocks, andcutlery sets. In one example, a knife block is disclosed that has ablock body, knife storage slots in the body, and first and second knifesharpeners aligned with first and second slots of the storage lots,respectively. In one example, the first and second knife sharpeners areeach specifically configured to contact a blade of a different knifestored in the corresponding first and second slots. In one example, acutlery set is disclosed that has a plurality of knives and a knifeblock with a block body, knife storage slots in the body, and at leastone sharpener aligned with a first slot of the storage slots. In oneexample, the first slot is configured and arranged to store a specificknife of the plurality of knives. The sharpener can be configured tocontact and sharpen a cutting edge of the specific knife when the knifeis inserted into the first slot, removed from the first slot, or both.These and other objects, features, and advantages of the disclosedcutlery sets and knife blocks will become apparent to those havingordinary skill in the art upon reading this disclosure.

The term “substantially” may be used herein with reference todimensions, sizes, angles, and the like. The term is intended to meanthat two characteristics, when compared to another as being the same asone another may not in fact be exactly the same as one another. Thedifferences may be permissible within normal manufacturing tolerances ormay be reasonable minor differences understood among those havingordinary skill in the art.

Turning now to the drawings, FIGS. 1-5 show one example of a cutlery set20 constructed in accordance with the teachings of the presentdisclosure. FIG. 2 shows a partially exploded view of the cutlery set 20and FIG. 3 shows a side view. FIGS. 4 and 5 show different views of thecutlery set in partial cross-section. The cutlery set 20 generally has aknife block 22 and a plurality of cutting implements. In this example,the cutting implements of the cutlery set 20 include kitchen shears orkitchen scissors 24, eight steak knives 26, a bread knife 28, a Santokuknife 30, a utility knife 32, a paring knife 34, and a chef's knife 36.As will be evident to those having ordinary skill in the art uponreading this disclosure, the size, shape, and fabrication materials andmethods of the knife block 22 can vary within the spirit and scope ofthe present disclosure. Likewise, the number and types of cuttingimplements and the details of each specific cutting implement can alsovary from the examples disclosed and described herein. The cutlery set20 described herein is just one of many possible examples of such a set.

The kitchen scissors 24, if provided as part of the cutlery set 20, canbe of a conventional or typical construction and are not furtherdescribed herein. Each of the knives 26-36 can also have a conventionalconstruction, but the details of each knife can vary. A number of thebasic features of most knives are referred to herein using referenceletters and these reference letters are commonly used for each of theknives 26-36. A few features of each knife, and particular those aspectsthat are of interest herein and/or those aspects that are substantiallydifferent in comparison to the other knives, are identified herein usingreference numbers unique to each knife.

In the disclosed example, the cutlery set 20 includes eight steak knives26, with only one shown as withdrawn from the knife block 22 in FIG. 2.The cutlery set 20 could include no steak knives or could include moreor less that the eight steak knives 26 that are shown herein. Each steakknife 26 has a handle 40 and a blade 42 extending from one end of thehandle. The blade 42 terminates at a point P at the free end of theblade. The blade 42 has a cutting edge 44 that extends lengthwise fromthe point P to a heel H of the blade, which is adjacent or near thehandle 40. The cutting edge 44 is the honed, thin, sharp surface or edgeof the blade 42. The blade 42 also has a spine S with is the edge of theblade opposite the cutting edge 44. The spine S is typically thickerthan the cutting edge 44 and provides weight and strength or rigidity tothe blade. The blade 42 has a bolster X that is opposite the blade pointP, is adjacent the heel H, and is a thicker part of the blade that joinsthe blade to the handle 40. A return R is typically positioned betweenthe bolster X and the heel H. The handle 40 has a grip section G that isformed for a user to grasp and manipulate the knife 26. The handle 40terminates at a butt Y or butt end that is the free end of the handleand has a handle guard Z in the form of a downward protruding portion orlip near the butt. The handle guard Z can aid in preventing a user'shand from slipping while using the knife 26.

Though not shown herein, the handle on many knives is formed having twoseparate halves or scales that are attached to a tang of the blade thatextends into the handle. Often rivets or pins are used to secure thescales to the tang of the blade. The particular handle and bladeattachment construction is not of particular relevance to the disclosureand is thus not mentioned any further here. As will be evident to thosehaving ordinary skill in the art, the shape, construction, andconfiguration of the handle 40 and the tang portion of the knife blade42 can vary as well.

Features and details of the cutting edge can also vary for a givenknife. A cutting edge of a knife typically has a grind (what the sharpedge looks like in cross-section) and a profile (what the cutting edgelooks like from the side). The grind is the macro-formed V-likecross-section shape of the blade that will ultimately form the cuttingedge when the blade is manufactured. The grind of the blade can be ahollow grind, a flat grind, a sabre grind, a chisel grind, a beveledgrind (double, compound, etc.), a convex grind, or the like. The grindis not of particular relevance to the disclosure, other than it mightdictate the particular type of or details for a sharpener elementutilized for a specific knife, as discussed below. The sides of theblade between the cutting edge and the spine S can be smooth and flat(except for the grind contour) or can include indentations, dimples,holes, or the like. The profile of the blade relates to whether thecutting edge is straight or serrated and whether the cutting edge islinear or curved. A cutting edge can include more than one type ofprofile over its length.

In this example, the cutting edge 44 of the steak knife 26 has aserrated portion T (with teeth) nearer the point P and a straightportion F nearer the heel H. The cutting edge 44 is also curved from theheel H to the point P. In general, the steak knife 26 has a blade lengthfrom the point P to the bolster X, a blade width between the bladesides, and a blade height between the spine S and the cutting edge 44.The height varies from the point P to the heel H because the cuttingedge has a curved profile. The maximum height of the blade 42 is at thereturn R, as the heel H of the cutting edge curves downward away fromthe spine S adjacent the bolster X.

A knife blade can be fabricated from stainless steel, carbon steel, highcarbon stainless steel, titanium, ceramic, plastic, or other suitablematerials, alloys, composites, laminates, and the like. The blades canthus be forged, molded, stamped, or the like. A knife handle can beformed of virtually any suitable material as well, such as wood, steel,aluminum, plastic, composites. The handles and blades of the disclosedknives and cutlery set are not intended to be limited in any way to aparticular material or manufacturing process.

The bread knife 28 has a handle 46 that is similar in size and shape tothe handle 40 of the steak knife 26. However, the handle 46 can bedifferent, if desired. The bread knife 28 also has a long blade 48 witha serrated cutting edge 50 from the point P to the heel H. The cuttingedge 50 is substantially linear as well from the heel H to the point Pand the blade has a consistent height over much of its length. The spineS is curved toward the cutting edge 50 nearer the point P.

The Santoku knife 30 has a handle 52 and a long and large blade 54 witha straight cutting edge 56. The cutting edge 54 is slightly curved (seeFIG. 4), more noticeably nearer the point P than at the heel H. Thehandle 52 is also similar in size and shape to the handle 40 of thesteak knife 26, but again the handle can be different, if desired. Thespine S also curves sharply toward the cutting edge 56 nearer the pointP. In this example, the blade height between the cutting edge 56 and thespine S near the bolster X is much greater than the height of the handle52. This creates a finger guard 58 on the back side of the blade betweenthe return R and the bolster X. The finger guard can keep a chefs handfrom slipping onto the blade during use. Such a finger guard can beprovided on the other knives of the cutlery set 20, if desired.

The utility knife 32 has a handle 60 that is similar in shape to thehandles 40, 46, and 52, but not in size. The handle 60 is smaller insize. The utility knife 32 has a blade 62 with a straight cutting edge64 and a gradually tapering height between the spine S and cutting edge64 from the bolster X to the point P.

The paring knife 34 also has a handle 66 that is similar in shape to theother handles, though the handle is smaller in size than even theutility knife handle 60. The paring knife 34 has a short blade 68 with astraight but curved cutting edge 70. The height of the blade 68 alsotapers between the spine S and cutting edge 70 from the heel H to thepoint P. The width of the blade 68 can be less than or thinner than thewidth of the other blades of the knives 26-32 and 36 of the cutlery set20.

The chef's knife 36 has a handle 72 that is similar in shape but largerin size than the other handles. The chef's knife 36 also has a long andlarge blade 74 with a straight cutting edge 76 that is curved, more sonearer the point P. The spine S is somewhat linear and the cutting edgeinstead curves upward toward the spine nearer the point P. The blade 76can be wider than the other blades of the knives 26-34 of the cutleryset 20.

Based on the foregoing, the cutlery set 20 can include a plurality ofknives. One or more of the knives of the cutlery set 20 can have adifferent blade characteristic in comparison to the other of the knivessuch as a blade length, a blade width, a blade height, a cutting edgeprofile, a cutting edge grind, or the like. The width, height, and shapeof the bolster on the knives can vary. The length, width, grip shape,finger guard shape, or the like of the handles can also vary. Inaccordance with the teachings of the present disclosure, the cutlery set20 can include at least one knife with a straight cutting edge than canbe sharpened without resorting to professional help or withoutdestroying the cutting edge, as will become evident below.

With reference to FIGS. 3-5, the knife block 22 of the cutlery set 20generally has a block body 80 that has a polyhedron shape. The blockbody 80 has a bottom 82 that is configured to rest on a surface, such asa countertop. The bottom 82 can include anti-skid pads 84 or some othertype of integral or attached legs or feet that elevate the block bodyabove the surface. Alternatively, the bottom 82 can be configured torest directly on the surface. The block body 80 also generally has afront 86, opposed sides 88, and a back 90 that in this example form thepolyhedron body shape. The block body 80 also has a stepped top or knifereceiving side with a lower step or knife receiving surface 92 above thefront 86 and an upper step or knife receiving surface 94 above the lowerknife receiving surface. The upper and lower knife receiving surfaces92, 94 are vertically separated by a wall segment 95.

The polyhedron shape of the block body 80 in this example has a veryangular look with each of the bottom 82, front 86, sides 88, and back 90having a polygonal shape. However, as will be evident to those havingordinary skill in the art upon reading this disclosure, the shape andconfiguration of the knife block 22, and particularly the block body 80,can vary considerably within the spirit and scope of the presentinvention. The body can be rounded, circular, semi-spherical, square,rectangular, cuboid, triangular, pyramidal, or the like. The body canhave an odd, irregular shape and can incorporate any combination ofrounded, curved, flat, or angular surface contour. The body need nothave a discernible front, back, or sides and need not have a discernibletop side and the one or more knife receiving surface can be in a top, afront, a back, a side, or any other suitable surface of the body.

The disclosed knife block 22 has a plurality of storage slots formedinto the block body 80, and particularly into one of the lower or upperknife receiving surfaces 92 or 94, for receiving one of the cutleryimplements described above. In this example, the plurality of storageslots includes an array of steak knife storage slots 96 formed into thelower knife receiving surface 92 of the block body 80. Each storage slot96 of the array is configured to receive and store one of the steakknives 26. Each storage slot 96 is thus sized having a length into theblock body 80 at least sufficient to receive the length of a blade 42 ofone of the steak knives 26. Each storage slot 96 is also sized having awidth at least sufficient to receive the width of the blade 42 of thesteak knife 26. Each slot 96 is also sized having a height at leastsufficient to receive the maximum height of the blade 42 of the steakknife 26. In this example, the height of each slot 96 is excessive inthe direction of the spine S of the blade 42 and the length of each slotis also excessive beyond the point P at the end of the blade 42, asshown in FIGS. 4 and 5. The width of each slot 96 can also be slightlywider than the blade 42 so that a narrow portion of the handle 40attached to the bolster X can seat in the slot as shown in FIGS. 1, 4,and 5. In this way, the slots 96 can position the steak knives 26 withthe handles 40 borne against the lower surface 92 surrounding the slot.The opening into each slot 96 can also be chamfered, if desired, inorder to guide the handle portion of the handle 40 into the slot when asteak knife 26 is inserted into the knife block 22.

The plurality of storage slots can also include a scissor slot 98 formedinto the block body 80 for storing the scissors 24. In this example, thescissor slot 98 is formed in the front 86 of the block body 80. Thescissors 24 can be inserted blades first into the scissor slot 98 tostore the scissors 24 in the knife block 22. The scissor slot 98 canalso be sized having a length at least sufficient to receive the bladesof the scissors and can have a width and height at least sufficient tofit or accommodate the blades of the scissors, leaving the handle ends100 of the scissors 24 exposed.

With reference to FIGS. 2, 4, and 5, the plurality of storage slots inthe block body 22 can also have a number of storage slots that arespecifically sized to receive a particular one of the other cutleryimplements of the set 20. In this example, each of the additionalstorage slots (described below), the steak knife slots 96, and thescissor slot 98 can optionally have an excessive length in comparison tothe particular cutlery implement to be stored therein. In one example,some or all of the storage slots in the block body 80 can extendcompletely through the block body. In this example, the steak knifeslots 96 open both into the lower step 92 and into the bottom 82 of theblock body 80. With reference to FIG. 6, the scissor slot 98 can alsoopen both into the front 86 and into the bottom 82 of the block body 80.In other examples, any one or more of the storage slots disclosed hereincan instead be a blind slot that terminates within the block body 80.

With reference to FIGS. 4-6, the block body 80 has a recess or arecessed portion 102 formed into the upper stepped surface or knifereceiving surface and/or first surface 94. The recess 102 may be atleast partially defined by a second surface 103. The purpose of therecess 102 is discussed below. In this example, the plurality of storageslots can include one or more, and in this case one spare storage slot104. The spare storage slot 104 is open into the upper knife receivingsurface 94 adjacent to but not within the recess 102. One or more suchspare storage slots 104 can be provided so as to allow a user to addknives or other cutlery implements to the cutlery set 20, if desired.The plurality of storage slots can further include a bread knife slot106 that is configured having a length, width, and height at leastsufficient to receive and store the blade 48 of the bread knife 28therein. For reasons discussed below, the bread knife slot 106 is alsoopen into the upper knife receiving surface 94 adjacent to but notwithin the recess 102.

The plurality of storage slots can further include one or more slotsthat each open into the recess 102 within the upper knife receivingsurface 94. One of these slots is a Santoku knife slot 108 (see FIGS. 2and 4-6) for storing the Santoku knife 30. The Santoku knife slot 108 inthis example extends completely through the block body 80 and opens inpart into the bottom 82 and in part into a vertical segment 110 of theback 90 of the body. The Santoku knife slot 108 can have a length thatis at least sufficient to receive the length of the blade 54 of theSantoku knife 30, a width at least sufficient to accommodate the widthof the Santoku knife blade, and a height at least sufficient toaccommodate the maximum height of the Santoku knife blade, as shown inFIGS. 4 and 5. The size of the Santoku knife slot 108 can be larger thanthe size of the bread knife slot 106 and the steak knife slots 96because the Santoku knife has a longer, wider, and taller blade 54.

The plurality of storage slots can also include a utility knife slot 112for storing the utility knife 32 and a paring knife slot 114 for storingthe paring knife 34. Each of the slots 112, 114 is also open into therecess 102 within the upper knife receiving surface 94. Each of thesestorage slots 112, 114 can be sized to specifically accommodate theblade size of the utility knife blade 62 and the paring knife blade 68,respectively, which have different size characteristics. Each can have alength that is at least sufficient to receive the corresponding blade.Again, the utility knife slot 112 and paring knife slot 114 can eachextend completely through the block body 80, as in this example, or canbe blind slots that terminate within the body. Each slot 112, 114 canalso have a width and height to accommodate the specific width andheight of the respective utility and paring knife blades 62, 68, whichcan also be of different size. The plurality of storage slots can alsoinclude a chefs knife slot 16 that opens into the recess 102 within theupper knife receiving surface 94. Again, the chefs knife slot 116 canextend completely through the block body 80 or can be a blind slot thatterminates within the body. The length, width, and height of the chefsknife slot 116 can again be sized to accommodate the specific length,width, and height of the chefs knife blade 74, which is much larger thanthe paring knife blade 68, for example. Thus, the chefs knife slot 116can be much larger in size (i.e., length, width, and/or height) than theparing knife slot 114 and the utility knife slot 112.

In view of the foregoing, it should be evident to one having ordinaryskill in the art that the number, sizing, and arrangement of theplurality of storage slots in the knife block 22 can be varied form theexample shown. The arrangement of the various storage slots relative toone another can be altered. The steak knife slots and/or the bread knifeslot can be eliminated. The number of steak knife slots can be reducedor increased, as can the number and/or type of the remaining cutleryimplement slots.

As shown in FIGS. 6 and 7, the knife block 22 as disclosed herein has aninsert assembly 120 that is sized to fit the recess 102 and that ismounted substantially within the recess. The recess 102 in this examplehas a rectangular shape and has a depth into the upper knife receivingsurface 94. The insert assembly 120 has a block insert 122 that has arectangular shape with an upper face plate 124, a surrounding side wall126, and a somewhat hollow underside 128 within the side wall and underthe face plate. The side wall 126 is sized to fit in the recess 102. Theupper face 124 has a lip 130 that protrudes radially outward relative tothe side wall 126 and rests on the upper knife receiving surface 94around the recess 102 (see FIG. 4). The underside 128 of the blockinsert 122 is generally hollow in this example but has a plurality ofribs that extend across the block insert. The plurality of ribs can addrigidity and strength to the structure, but in this example are alsoprovided for another purpose.

The face plate 124 has a plurality of openings through the plate thatare positioned to coincide with the storage slots within the recess 102.Specifically, the face plate 124 has a Santoku knife opening 132 that isaligned with the Santoku knife slot 108 with the block insert 122installed in the recess 102. Likewise, the face plate 124 has a utilityknife opening 134, a paring knife opening 136, and a chefs knife opening138 that are respectively aligned with the corresponding utility knifeslot 112, the paring knife slot 114, and the chefs knife slot 116 withinthe recess 102. The plurality of ribs includes a first spaced apart ribpair 140 that creates a Santoku knife sub-slot 142 on the underside 128of and through the block insert 122. The Santoku knife sub-slot 142 isaligned with both the Santoku knife opening 132 in the face plate 124and the Santoku knife slot 108 in the block body 80. A second rib pair144 creates a utility knife sub-sot 146 through the block insert 122that is aligned with both the utility knife opening 134 in the faceplate 124 and the utility knife slot 112 in the block body 80. A thirdrib pair 148 creates a paring knife sub-slot 150 through the blockinsert 122 that is aligned with both the paring knife opening 136 in theface plate 124 and the paring knife slot 114 in the block body 80. Afourth rib pair 152 creates a chef's knife sub-slot 154 through theblock insert 122 that is aligned with both the chef's knife opening 138in the face plate 124 and the chef's knife slot 116 in the block body80.

A cover plate 160 can be attached, adhered, or otherwise mounted to theface plate 124 of the block insert, if desired. The cover plate includesa plurality of holes 162, 164, 166, and 168 that each overly and alignwith the Santoku knife opening 132, the utility knife opening 134, theparing knife opening 136, and the chef's knife opening 138,respectively, when the cover plate is mounted on the face plate 124 ofthe block insert 122. The cover plate 160 can be a decorative item toimprove the ornamental appearance of the cutlery set 20. The cover plate160 can be a laminate structure with a decorative or ornamental surfaceor can be a homogeneous structure. The cover plate 160, or at least theexposed surface layer, can be formed of wood, plastic, stainless steel,aluminum, titanium, platinum, or the like and/or can be finished toachieve a desired appearance. Also, the block insert 122 can be a moldedplastic, one piece component or can be fabricated from wood, steel,aluminum, or the like. The face plate 124 can define the exposed surfaceover the recess 102, eliminating the cover plate 160 altogether, ifdesired.

As used herein below, the term “storage slot” may refer to the combined,knife blade receiving, aligned slots in the block body 80, sub-slots inthe block insert 122, openings in the face plate 124, and holes in thecover plate 160. Thus, when referring to one of the cutlery implementsbeing inserted into or withdrawn from its respective storage slot, theimplement may be passing into, though, and/or out of the correspondingslot, sub-slot, opening, and hole.

In the disclosed example, the cutlery set 20 employs a plurality ofsharpening elements 170 that coincide with respective storage slots forthe Santoku knife 30, utility knife 32, paring knife 34, and chef'sknife 36. Each sharpening element is carried on or is a part of theinsert assembly 120. See the sharpening element 170 for the Santokuknife 30 in FIG. 8 and portions of the sharpening elements 170 in FIGS.6, 7, and 9. The sharpening elements are shown having essentially thesame construction so only one of the sharpening elements is describedherein. The description applies equally to the other of the sharpeningelements. However, the sharpening elements can each be configureddifferently (from one another and/or from the disclosed example). Forexample, the sharpening elements can each be specifically configured toprovide the desired sharpening characteristics to the correspondingknife blade cutting edge and to accommodate the surface angles and/orthe grind shape for the corresponding knife cutting edge.

With reference to FIGS. 6-9, each sharpening element 170 has a stoneholder 172 associated with each of the sub-slots 142, 146, 150, and 154on the underside and/or interior surface 128 of the block insert. Thestone holder 172 can be integrally molded as a part of the block insert122, as in this example, or can be a separate element attached to theunderside. The stone holder 172 has a recess or hollow shape upwardtoward the face plate 124. With regard to the Santoku knife storageslot, a lower end of the opening 132 and sub-slot 142 aligns with afirst notch 173 created by the stone holder 172. The stone holder 172defines a first stone pocket 174 oriented at an angle relative to theopening and sub-slot. A first sharpening stone 176 is seated in thefirst stone pocket 174. In this example, both the first stone pocket 174and the first sharpening stone 176 have a rectangular cuboid shape. Eachsharpening element 170 also has a cap 178 that is similarly shaped incomparison to the stone holder 172. In other words, the cap 178 has arecessed or hollow interior and defines a second stone pocket 180therein. A second sharpening stone 182 is seated in a second stonepocket of the cap 18 and each essentially identical to the first stonepocket 174 and sharpening stone 176 in this example. However, the secondstone pocket 180 is also oriented at an angle relative to the opening132 and sub-slot 142, but in the opposite direction relative to thefirst stone pocket 174. A second notch 184 in the cap 178 coincides withthe first notch of the stone holder 172 when the sharpening element 170is assembled.

The cap 178 covers the stone holder 172 as shown in FIGS. 8 and 10A anda cavity is formed between them defined by the recesses of the matingparts. The first and second sharpening stones 176 and 182 are capturedin the cavity within their respective stone pockets 174 and 180. Thefirst stone pocket 174 and second stone pocket 180 are arranged tocreate a V-shape and thus the first and second sharpening stones 176 and182 are arranged in the V-shape, as shown in FIGS. 6-8 and 10B. Also,the valley or wedge of the V-shape created by the sharpening stones 176,182 is exposed within the first and second notches 173, 184. Thus, whenlooking into the Santoku knife storage slot (see FIG. 10B), one can seethe V-shape or wedge of the sharpening stones 176, 182.

The caps 178 can also be made of plastic or can be made of othersuitable materials, if desired. If both the stone holders 172 and thecaps 178 are formed of plastic, the two parts can be heat weldedtogether. For example, one of the two parts (stone holder 172 or cap178) can be provided with one or more pins 184 and the other of the twoparts can be provided with a like number of holes 186. The pins can bereceived within the holes to align the two parts when assembled and canthen be heat welded to secure the two parts together. In other examples,fasteners could be used to assemble the holders and caps, which mightallow a user to disassemble the sharpening elements to replace thesharpening stones 176, 182, if and as needed.

Though one particular sharpening element configuration is disclosedherein, other configurations are certainly within the spirit and scopeof the present invention. The invention is not necessarily limited toonly the one example given. The sharpening elements can be complete andseparate devices attached to the slots in the knife block 22, attachedto the block insert 122, or the like. The sharpening stones can bechanged in type and shape, and can be installed, assembled, and/or heldin place in different ways. Other sharpening materials can be usedinstead of stones. The stones can be natural or synthetic and the gritof the stones can vary as desired.

Likewise, the included angle, i.e., the V-shape or sharpener anglecreated by the angled sharpening stones or sharpening elements can bevaried. One's attention is drawn to FIG. 10C as a reference for thefollowing description. In one example, each of the knives (such as theutility knife 32 and its blade 64 shown in FIG. 10C) can have the sameblade angle θ and each of the sharpening elements 170 (the stones 178,182 in this example) can define a V-shape with the same angle ψ. Forreasons discussed immediately below, the sharpener angle ψ can begreater than the blade edge angle θ. In another example, two or more, oreven each, of the blades of the cutlery set can have a different bladeangle θ in comparison to other blades of the set. In such an example,the V-shape of the sharpener angle ψ of each sharpening element can bedifferent to accommodate the blade edge angle θ for a specific knife ofthe set. Alternatively, each of the sharpener elements can have the samesharpener angle ψ, which can be larger than the largest blade angle ofthe blades of the cutlery set.

In each instance, the V-shape of the sharpener angle ψ can be largerthan the blade edge angle θ in a given knife slot as depicted in FIG.10C. With such an arrangement, the tip of the knife edge on the bladewill be sharpened each and every time from the first insertion andwithdrawal of the knife from the slot. This would occur, regardless asto whether the knife edge were run over the sharpening element exactlyvertical or offset slightly from vertical, as shown in FIG. 10C. If thisangular arrangement is not used, it may take considerable time beforethe knife edge of the blade is properly sharpened during insertion andremoval. In one illustrative example, the blade angle θ can be about 40degrees and the sharpener angle ψ can be about 45 degrees. In anotherillustrative example, the blade angle can vary between 32-40 degreesamong the cutlery set knives and each sharpener angle can again be about45 degrees. Alternatively, the sharpener angle ψ for each sharpeningelement can be specific to and a few degrees greater than the particularblade angle θ of the knife to be stored in a given storage slot.

With reference to FIGS. 10A-10C and 11, when a user inserts or withdrawsone of the knives associated with one of the sharpening elements 170from the specific storage slot for that particular knife, the cuttingedge can be drawn across the stones within the storage slot. This cansharpen the cutting edge of the blade each time the knife is inserted orwithdrawn. The width of the blade and the width of the slot can be suchthat the blade is held precisely perpendicular between the twosharpening stones so as to properly and consistently sharpen the blade.

Also with reference to FIGS. 3 and 11, a bolster angle β created betweenthe lengthwise axis of the knife, such as the Santoku knife 30, and theknife bolster X. Likewise, a face angle α is created between the knifereceiving face of the block body 22, the upper knife receiving surface94 in this example, and the lengthwise axis of the knife storage slots(which is the same as the angle of the back 88 of the knife block 22 inthis example). Further, in one example, the knife lengthwise axis angleand/or the slot axis angle μ relative to a horizontal reference can bebetween about 40 degrees and about 55 degrees for each of the knifestorage slots. In one more specific example, the angle μ can be betweenabout 42 degrees and about 48 degrees, and in one particular example canbe about 45 degrees relative to a horizontal reference. In anotherparticular example, the angle μ can be about 52.5 degrees. The angle μ,however, need not be the same for each of the different knife storageslots. The angle μ can be different among one or more of the storageslots that pass through the insert assembly 120, i.e. among the slotsthat have a sharpening element. Or, the storage slots can all have thesame angle. The angle μ for the knives that do not have a storage slotsharpening element can also be different than that of the knives withsharpener elements, or the angles can be the same.

In one example, the bolster angle β and the face angle α can be the sameor substantially the same (i.e., the same within manufacturingtolerances or the same within a degree or two). During use, when a userwithdraws or inserts a knife, such as the Santoku knife 30 relative toits respective storage slot, this angular relationship can create twobenefits or advantages. First, in general, the exact value of the anglesα and β may not be specifically important. However, having these anglesequal to one another may allow the knife to sit securely in the block.This can prevent wobble and allow for as much of the blade as possibleto be sharpened. If these angles do not match, then the knife blade maynot be insertable all the way into the block. This can prevent a portionof the blade being sharpened. Also, with the angles being equal and, inone example, about 113 degrees (23 degrees from a horizontal reference)as shown in FIG. 11, the specific angle can allow the center of gravityof the knives to rest to the right in the drawing (interior to the knifeblock 22), i.e., beyond the fulcrum formed by the sharpener elements.This can allow 1) better contact between cutting edge and sharpeningstones and inhibited or no tipping of the knives with respect to theknife block and 2) the ability to reduce the overall block anglerelative to the horizontal reference as much as possible to facilitateengagement between the cutting edge and the sharpener element. Thebolster angle β and face angle α can vary, depending on the design ofthe knives and their balance or center of gravity.

With reference to FIGS. 6 and 7, the disclosed cutlery set 20 caninclude at least one sharpening element 170 that is associated with oneslot of the plurality of storage slots. This one slot can be configuredto accept a specific blade size and shape of a particular knife to bestored within the slot. The cutting edge of the blade can then contactthe sharpening stones 176, 182 when the knife is inserted into andwithdrawn from the one slot. In one example, the cutlery set 20 caninclude a first slot and a second slot of the plurality of storage slotsand each can include a separate sharpening element 170 associated withthe respective slot. Both the first and second slots can be configureddifferently and to accept a specific blade size and shape. In thedisclosed example, the cutlery set 20 includes four different knives 30,32, 34, and 36 that each have a sharpening element 170 associated withthe respective storage slot.

It is known that cutting edges with serrated blade profiles are not wellsuited for conventional consumer-friendly sharpeners or consumer-capablesharpening techniques. Thus, one or more of the plurality of storageslots may not include a dedicated sharpening element 170 associated withthat particular slot. In the disclosed example, the bread knife 28 has aserrated cutting edge 50 on its blade 48 and the steak knives 26 eachhave a partly serrated cutting edge 44 on their blades 42. Thus, thesteak knife slots 96 and the bread knife slot 106 do not have anassociated sharpening element. The spare knife slot 104 in this examplealso does not include a dedicated sharpening element 170. This is so theconsumer can add a knife with a serrated edge to the cutlery set, ifdesired.

In the disclosed example, each of the Santoku knife 30, the utilityknife 32, the paring knife 34, and the chef's knife 36 has a straightcutting edge 56, 64, 70, and 76, respectively. Each of these blades 54,62, 68, and 74 can be sharpened using a conventional sharpening elementand technique. Thus, each of the corresponding slots 108, 112, 114, and116 has an associated sharpening element 170 in the disclosed cutleryset 20. As shown in FIGS. 4. 5, and 10A, the sharpening elements 170 arepositioned so that a substantial majority or the entirety of thecorresponding cutting edges can contact the sharpening stones 176, 182during insertion and withdrawal of a knife from its storage slot. Withreference to FIG. 5, the Santoku knife 30, Santoku knife slot 108 (andentire storage slot), and the associated or respective sharpeningelement 170 are aligned and positioned so that the sharpening stones176, 182 rest adjacent or very near the heel H of the cutting edge 56when the knife is stored in its specific storage slot. As a result, thestones 176, 182 can very easily, and almost assuredly will, contact thecutting edge 56 of the blade 54 on the Santoku knife 30 as it isinserted or withdrawn from its respective storage slot.

As noted above, each of the storage slots with an associated sharpeningelement 170 can be specifically configured in length, width, and/orheight to accept a particular one of the cutlery implements of the set20. In one example, the size of the openings 132, 134, 136, and 138 inthe face plate 124 (and/or the size of the holes 162, 164, 166, 168 inthe cover plate) may help a user determine which cutlery implementshould be stored in which storage slot. This might work well for thelarger knives, which won't fit in the smaller sized storage slots.However, this might not work as well if a user inserts a smaller knifein a larger sized storage slot because the knife will fit even thoughthe larger storage slot is not the correct slot for that particularknife. Thus, the cutlery set 20 can be provided with indicia that willindicate to a consumer which particular cutlery implement should bestored in which particular storage slot. The indicia can be used for allof the implements and storage slots of the cutlery set 20, or can beprovided only for a sub-set that includes the storage slots with adedicated sharpening element 170.

One example of indicia used in such a manner is shown in FIGS. 1, 2, and5. Alphanumeric letters are applied in this example to the butt Y of thehandles 52, 60, 66, and 72 of the Santoku knife 30, utility knife 32,paring knife 34, and chef's knife 36. The Santoku knife is marked withthe letter A, the utility knife is marked with the letter B, the paringknife is marked with the letter C, and the chef's knife is marked withthe letter D. The cover plate 160 also includes matching indiciaadjacent each of the storage slot holes 162, 164, 166, and 168. Thecover plate indicia can be identical to the indicia on the knives or canat least have the same identifying criteria, as in this example. TheSantoku knife storage slot hole 162 is marked with the phrase “Knife A”,which matches the letter A on the Santoku knife handle 52. Likewise, theutility knife storage slot hole 164 is marked with “Knife B” to matchthe letter Bon the utility knife handle 60. The paring knife storageslot hole is marked with “Knife C” to match the letter C on the paringknife handle 66. The chef's knife storage slot hole 168 is marked with“Knife D” to match the letter D on the chef's knife handle 72. The usercan match the indicium on the butt Y of a particular knife handle to thecorresponding indicium on the cover plate 160 for the correct storageslot when trying to determine the storage slot in which to place andstore a particular one of the knives.

The form of indicia used can vary within the spirit and scope of thepresent disclosure. The indicia can be single or multiple symbols,pictures, numbers, letters, combinations thereof, or the like. FIG. 12shows one example of a cutlery set 190, which has a knife receivingsurface 192 on a knife block with three storage slots 194, 196, and 198,each with an associated sharpening element 170 aligned therewith. Thecutlery set 190 also has three knives 200, 202, and 204. In thisexample, each knife is shown having numeric indicia with the knife 200marked with the number 1, the knife 202 marked with the number 2, andthe knife 204 marked with the number 3. Similar to the prior embodiment,the knife receiving surface 192 (either directly on the block, on aninsert face plate, on a cover plate, or the like) is marked withmatching, though not identical, indicia using a combination of lettersand numbers. The storage slot 194 for the knife 200 is marked with“Knife 1”, the storage slot 196 for the knife 202 is marked with “Knife2” and the storage slot 198 for the knife 204 is marked with “Knife 3”on the surface adjacent each slot. FIG. 13 shows another example of acutlery set 210 that includes six knives 212, a knife receiving surface214 on a knife block, and six corresponding knife storage slots 216. Theindicia are identical on both the knives 212 and the knife receivingsurface 214. In this example, the indicia utilize only the numbers 1-6on each of the knives 212 and adjacent each of the storage slots 216. Inthis example, all six of the storage slots 216 also have a dedicatedsharpening element 170 aligned with the slot. Again, it may be that onlyone knife or only first and second knives (of a three or more knife set)and only one slot or only first and second slots (of three or morestorage slots) of a cutlery set are provided with matching indicia. Itmay also be that each and every implement and slot are provided withcorresponding or matching indicia, though some of the storage slots donot have a dedicated sharpener element.

As noted above, the cutlery sets disclosed herein can vary with regardto the number and type of cutlery implements. As a result, the knifeblock can vary in the number of the storage slots for the implements.Also, the arrangement of the storage slots on the knife block can alsovary from the examples shown and described herein. For example, FIG. 14shows a top side view of a knife block 220 with only three storage slots222 formed in a surface 224 of the block. The three storage slots 222are also arranged in a different pattern compared to the earlierembodiment. FIG. 15 likewise shows a top side view of another example ofa knife block 230 with six storage slots 232 formed in a surface 234 ofthe block. The six storage slots 232 are arranged in another differentpattern in comparison to the earlier embodiments. As will be evident tothose having ordinary skill in the art upon reading this disclosure, thedisclosed cutlery sets can vary considerably in the number, size,location, arrangement, and the like with regard to the knife storageslots and cutlery implements. Also, the surfaces 224 and 234 in FIGS. 14and 15 can define an entire top side of the knife blocks 22, 230 or canrepresent only a surface portion or segment of a larger block.

Also as noted above, the size, shape, configuration, and construction ofthe disclosed knife blocks can also vary within the spirit and scope ofthe present disclosure. FIGS. 16 and 17 illustrate just two of manypossible alternate examples of such knife blocks. Each is illustratedusing essentially the same number and arrangement of knife storage slotsas the knife block 22. FIG. 16 shows a knife block 240 with a pluralityof steak knife slots 26 provided directly in a front 242 of the blockinstead of on a step or a part of a top side of the block. The remainingstorage slots are provided in a lone knife receiving surface 244 on thetop side of the block. Also, a back 246 of the knife block 240 iscurved, not planar or flat. FIG. 17 shows a knife block 250 with anupper knife receiving surface 252 and a lower knife receiving surface254, similar to the knife block 22. However, in this example, the knifereceiving surfaces 252 and 254 are convexly curved upward, lot flat orplanar. As will be evident to those having ordinary skill in the artupon reading this disclosure, the disclosed knife blocks can varyconsiderably in the size, shape, contour, curvature, angle, number ofsurfaces, angle or orientation of surfaces, and the like.

The disclosed knife blocks and cutlery systems aim to solve or improveupon the issue of maintaining a knife's edge over the life of the knife.This is accomplished by having an integrated sharpener element, such asa ceramic sharpener, in one or more of the specific knife storage slots.The cutting edge of the knife is sharpened when it is removed fromand/or inserted into its specific storage slot in the knife block.Providing a dedicated, fixed position sharpener element integrated intothe storage slot where a particular knife is stored allows the act ofsharpening the knife to become part of normal use of the knife (i.e. nota separate step that must be selectively performed by the consumer). Thesharpener elements or each sharpener element can be specificallydesigned for a particular knife and can be included with the cutleryset. Sharpening of the knives associated with a slot having a sharpeningelement is thus optimized in a very effective manner for such knives.The consumer need not become aware of when the knife needs to besharpened. Sharpening occurs upon the simple and regular act ofwithdrawing or inserting the knife in its particular storage slot.

In one example, the disclosed cutlery sets can include a wooden knifeblock designed to hold and store a specific set of knives. The sets canbe comprised of many different varieties and types of implements, suchas a 6 piece set, a 9 piece set, a 12 piece set, or the like. The knifeblock has a recess cut out or otherwise formed on the front or tops sideface. The recess is used to mount an injection molded part (insertassembly) that contains or carries all of the sharpener elements for agiven cutlery set. The insert assembly is then attached to the woodenblock. Screws or other fasteners can be used to pass through bores 260(see FIG. 9). The cosmetic faceplate or cover plate is then fixed to theface plate of the insert assembly, which can hide the fasteners andprotect the knife block substrate material against scratches from theknives.

The wooden knife block in one example can be designed in such a way thatthe orientation of the knives is as close to 45° as possible relative toa horizontal reference. This can facilitate easier engagement of theknives with the sharpener elements under force of gravity while reducingthe possibility of the block tipping over with the added forces thatmight result from the act of sharpening.

The insert assembly can house or define various configurations of knifestorage sub-slots depending on the particular cutlery set. Thesesub-slots are oriented vertically in a side-to-side direction tofacilitate knife engagement with the sharpener elements and to avoidbias towards left-handed or right-handed users. In the disclosedexamples, all of the storage slots that have a dedicated sharpenerelement are housed in the single insert assembly and can be sizedspecifically to fit a particular knife in that cutlery set. It ispossible for a given knife block to employ two or more such insertassemblies. It is also possible for a given knife block to have one ormore sharpener elements mounted directly to or within the knife block,separate from any insert assembly. However, providing a consolidatedinsert assembly as one part can make manufacture and assembly of thecutlery set easier and less cumbersome.

Each storage slot that has an associated sharpener element in oneexample can employ a pair of white ceramic sharpeners or stones. Eachsharpener can have a Rockwell hardness that is greater than that of thesteel or other material of the knife blades of the cutlery set. Theceramic sharpeners or stones can be oriented in a manner such that theyform a V-shape that is aligned with the given storage slot. The angleformed by the two stones can be referred to as the included angle or“sharpener angle”. This sharpener angle can be determined and selectedsuch that it can accommodate the manufacturing variation of thecorresponding edge angles on the knives. As noted above, each sharpenerelement can have a different included angle, if needed. Also as notedabove, each sharpener angle can be greater than the blade edge angle ofthe corresponding knife.

As noted above, serrated knives (bread knife, serrated utility knife,steak knife) are typically not sharpened or honed. If any such knivesare included in a cutlery set, the knife block can have storage slotsfor these types of knives with no sharpener element provided. Thesetypes of knives typically must be sharpened by a professional usingparticular techniques and sharpening tools.

The disclosed insert assembly can have a lip or flange around theperimeter of the assembly. The lip can serve to properly locate andposition the insert assembly in the recess to a particular depth bylying on the plane of the knife receiving surface of the knife block.Also, the insert assembly and recess opening in the block can beconfigured so as to properly align the sub-slots of the assembly withthe storage slots of the knife block. The insert assembly can also hideany variations and imperfections in the material of the knife block,such as those caused by manufacturing a recess in a wooden block.

The cover plate, regardless of the material used or the manufacturingprocess used, can also be labeled with the indicia using any suitableprocess, such as via in-molding, screen printing, pad printing, chemicaletching, or the like. Each label or slot indicia can then correspond toa matching label or knife indicia on the butt end of each knife. Thistype of labeling or indicia can give a user a visual clue as to whereeach knife is supposed to be stored in the knife block, helping to avoidimproper placement and storage.

Although certain cutlery sets, sharpener elements, and knife blockfeatures and components have been described herein in accordance withthe teachings of the present disclosure, the scope of coverage of thispatent is not limited thereto. On the contrary, this patent covers allembodiments of the teachings of the disclosure that fairly fall withinthe scope of permissible equivalents.

What is claimed is:
 1. A knife block, comprising: a block body; a blockinsert coupled to the block body, the block insert comprising a firstknife slot, a second knife slot, an exterior surface, an interiorsurface, a first sharpening element holder on the interior surfaceconfigured to receive a first sharpening element, and a secondsharpening element holder on the interior surface configured to receivea second sharpening element; a first cap attached to the firstsharpening element holder, the first cap having a first cavityconfigured to receive a third sharpening element, wherein the firstsharpening element is positioned at least partially between the interiorsurface and the third sharpening element; and a second cap attached tothe second sharpening element holder, the second cap having a secondcavity configured to receive a fourth sharpening element, wherein thesecond sharpening element is positioned at least partially between theinterior surface and the fourth sharpening element, wherein the firstsharpening element and the third sharpening element form a V-shape andare configured to sharpen a first knife upon removal of the first knifefrom the first knife slot, and wherein the second sharpening element andthe fourth sharpening element form a V-shape and are configured tosharpen a second knife upon removal of the second knife from the secondknife slot.
 2. The knife block of claim 1, wherein the first sharpeningelement is positioned to contact a first side of a cutting edge of thefirst knife when the first knife is inserted into the first knife slot,and wherein the third sharpening element is positioned to contact asecond side of the cutting edge when the first knife is inserted intothe first knife slot.
 3. The knife block of claim 1, further comprisinga cover plate mounted to the block insert and comprising first andsecond holes that overly and align with the first and second knifeslots, respectively.
 4. The knife block of claim 3, wherein the coverplate comprises a decorative surface comprising wood, plastic, stainlesssteel, aluminum, titanium, or platinum.
 5. The knife block of claim 3,wherein the cover plate is adhered to the block insert.
 6. The knifeblock of claim 1, wherein the block insert is coupled to the block bodywith screws.
 7. The knife block of claim 1, wherein the first, second,third, and fourth sharpening elements are ceramic.
 8. The knife block ofclaim 1, wherein the block insert is formed of plastic.
 9. The knifeblock of claim 1, wherein the first and second caps are formed ofplastic.
 10. The knife block of claim 1, wherein each of the first andsecond caps or the first and second sharpening element holders comprisesone or more pins, and each of the other of the first and second caps orthe first and second sharpening element holders comprises acorresponding number of holes, such that the pins are received withinthe holes to align the first and second caps and the first and secondsharpening element holders.
 11. The knife block of claim 1, wherein thefirst and second sharpening element holders are integrally molded as apart of the block insert.
 12. The knife block of claim 1, wherein thefirst and second sharpening element holders are attached to the interiorsurface of the block insert.
 13. The knife block of claim 1, wherein theblock insert is positioned at least partially within the block body. 14.The knife block of claim 1, further comprising a third knife slot thatdoes not have a knife sharpener aligned therewith.
 15. The knife blockof claim 1, further comprising first and second indicia associated withthe first and second knife slots, respectively, the first and secondindicia relating to one or more knife characteristics and the firstindicia being different than the second indicia.
 16. The knife block ofclaim 1, wherein the block body comprises first and second storage slotsaligned with the first and second knife slots, respectively.
 17. Theknife block of claim 16, wherein the first and second storage slotsextend completely through the block body.
 18. A cutlery set, comprising:a first knife with a first blade having a first blade edge angle; asecond knife with a second blade having a second blade edge angle; andthe knife block of claim 1, wherein the first sharpening element and thethird sharpening element form a V-shape having a first sharpener anglethat is greater than the first blade edge angle, and wherein the secondsharpening element and the fourth sharpening element form a V-shapehaving a second sharpener angle that is greater than the second bladeedge angle.
 19. The cutlery set of claim 18, wherein the first blade hasat least one size characteristic that is different than the secondblade.
 20. The cutlery set of claim 19, wherein the at least one sizecharacteristic is a blade length, a blade width, or a blade height.